Precast concrete structure and method of constructing the same

ABSTRACT

The pre-cast concrete structure of the present invention comprises a lower unit structure  110  having the lowest stage unit structure  111,  the middle stage unit structure  112,  and the highest stage unit structure  113  which are vertically orderly piled on another and wedged from each other; a middle unit structure  130  having the lowest stage unit structure  131,  the middle stage unit structure  132,  and the highest stage unit structure  133  which are vertically orderly piled on another and wedged from each other; and a upper unit structure  150  having the lowest stage unit structure  151,  the middle stage unit structure  152,  and the highest stage unit structure  153  which are vertically orderly piled on another and wedged from each other.

FIELD OF THE INVENTION

The present invention relates to a pre-cast concrete structure and a method of constructing the same, and more particularly, to a pre-cast concrete structure and a method of constructing the same enabling to guarantee an easy and reliable connection between unit structures from each other.

BACKGROUND OF THE INVENTION

The PC (pre-cast concrete) is a method in which unit structures having an easy making, storage and transport are manufactured in a factory and then they are assembled from each other on spot to form a structure or building, which is usually used in construction sites.

The representative example of this PC structure is disclosed in Korean Registered Patent No. 10-0733837 ┌Duplex 1 set pre-cast concrete pillar and Construct method using the same┘, and its representative structure is shown in FIGS. 1 and 2.

As shown in FIGS. 1 and 2, the pillar 10 is composed of a first and second PC pillar 10 a and 10 b which are bilaterally symmetrically formed, and each PC pillar 10 a and 10 b is composed of 3 stages of 1 set.

And, a plurality of vertical reinforcing rods 20 and slanted reinforcing rods 30 are installed to be exposed in the space formed between each pillar 11, 12 and 13, and PC bar 40 is connected to the space in later.

The first and second PC pillars 10 a and 10 b are firmly connected from each other by a plurality of connecting bolts 14 which pass through a plurality of bolt holes 15 formed horizontally there-through.

The PC structure having the above described structure has a problem in that lots of time and cost are required to manufacture the pillars 11, 12 and 13 and difficulty to store and transport them is followed because the first PC pillar 10 a and the second PC pillar 10 b which are bilaterally symmetrically formed should be manufactured at a factory by connecting each stage of pillars 11, 12 and 13 with the plurality of vertical and slanted rods 20 and 30.

Further, the plurality of connecting bolts 14 should be correctly fit in the plurality of bolt holes 15 to assemble the first PC pillar 10 a and the second PC pillar 10 b on site, which brings lots of difficulty to correctly perform every time even experts.

SUMMARY OF THE INVENTION

The present invention is created to solve a problem of the above-mentioned prior art, and accordingly one object of the present invention provides a pre-cast concrete structure and a method of constructing the same enabling to significantly reduce the time and cost required to manufacture a unit structure by manufacturing each unit structure such as the lowest one, the middle one and the highest one of them at a factory and then by easily piling them in their size and order.

Another object of the present invention provides a pre-cast concrete structure and a method of constructing the same enabling to significantly reduce the time and cost required to build a desired structure and to guarantee the safety of the built structure by using the unit structures.

In order to achieve the above-described objects, the present invention provides a pre-cast concrete structure comprising a lower unit structure 110 having the lowest stage unit structure 111, the middle stage unit structure 112, and the highest stage unit structure 113 which are vertically orderly piled on another and wedged from each other; a middle unit structure 130 having the lowest stage unit structure 131, the middle stage unit structure 132, and the highest stage unit structure 133 which are vertically orderly piled on another and wedged from each other; and a upper unit structure 150 having the lowest stage unit structure 151, the middle stage unit structure 152, and the highest stage unit structure 153 which are vertically orderly piled on another and wedged from each other.

In the pre-cast concrete structure of the present invention, all stage unit structures composed of the lower unit structure 110, the middle unit structure 130 and the upper unit structure 150 may be provided with a reinforcing rod guider 115 to guide a plurality of heavy reinforcing rods 2, respectively. Further, the reinforcing rod guider 115 may be composed of a plurality of inserting portions 116 to be inserted with the plurality of heavy reinforcing rods 2 and a plurality of connecting portions 117 to connect the plurality of inserting portions 116.

In the pre-cast concrete structure of the present invention, the lower unit structure 110, the middle unit structure 130 and the upper unit structure 150 may be further firmly combined by a bundle of tension wires 1 which pass through them.

Further, the lowest stage unit structure 111 may be provided with a wedge typed coupler 114 where a lower end portion binder 11 to bind the bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof.

Also, the middle stage unit structures 112 may be provided with a plurality of reinforcing rod couplers 116 which couple the plurality of heavy reinforcing rods 2 in the lower end portion thereof to be located near the through-hole through which the bundle of tension wires 1 are passed.

Herein, the plurality of reinforcing rod couplers 116 may have a upper portion and a lower portion in couple, the upper portion rightly standing up and the lower portion reversely standing up.

Further, the highest stage unit structure 113 may have the same structure with the middle stage unit structure 112.

In the pre-cast concrete structure of the present invention, the lowest stage unit structure 131 may be provided with a wedge typed coupler 134 where a lower end portion binder 31 to bind the bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof, and the wedge typed coupler 134 may be composed of the upper portion and the lower portion in couple, the upper portion rightly standing up and the lower portion reversely standing up.

Further, the lower end portion binder 31 inserted in the lowest stage unit structure 131 may be wedged in the upper portion, and the upper end portion binder 12 to bind another bundle of tension wires 1 protruded out the highest stage unit structure 113 is wedged in the lower portion.

In the pre-cast concrete structure of the present invention, the highest stage unit structure 153 may be provided with a wedge typed coupler 154 where a upper end portion binder 52 to bind the bundle of tension wires 1 is wedged to be intermediately located in the upper end portion thereof, the wedge typed coupler 154 reversely standing up.

The present invention also provides a method of constructing the pre-cast concrete structure comprising: (A) step for vertically orderly piling the lowest stage unit structure 111, the middle stage unit structure 112 and the highest stage unit structure 113 so as to make a lower unit structure 110; (B) step for vertically orderly piling the lowest stage unit structure 131, the middle stage unit structure 132 and the highest stage unit structure 133 so as to the middle unit structure 130; (C) step for vertically orderly piling the lowest stage unit structure 151, the middle stage unit structure 152 and the highest stage unit structure 153 so as to make the upper unit structure 150; and (D) step for vertically piling the middle unit structure 130 on the lower unit structure 110, and then vertically piling the upper unit structure 150 on the middle unit structure 130.

Further, the number of the middle unit structure 130 may be changed according to the height of the desired structure to be constructed.

According to the present invention, the time and cost required to manufacture a unit structure can be significantly reduced because each unit structure such as the lowest one, the middle one and the highest one of them are manufactured at a factory and then easily piled in their size and order.

The time and cost required to build a desired structure and to guarantee the safety of the built structure can be significantly reduced because the unit structures are applied.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the present invention will become readily apparent by reference to the following detailed description when considered in conjunction with the accompanying drawing wherein:

FIG. 1 is a cross sectional view schematically illustrating the conventional Duplex 1 set PC pillar;

FIG. 2 is a cross sectional view schematically illustrating the assembled structure of the conventional Duplex 1 set PC pillar;

FIG. 3 is a broken view schematically illustrating the PC structure according to a preferred embodiment of the present invention;

FIG. 4 is a cross sectional view schematically illustrating the lower unit structure in FIG. 3;

FIG. 5 is a cross sectional view schematically illustrating the middle unit structure in FIG. 3;

FIG. 6 is a cross sectional view schematically illustrating the upper unit structure in FIG. 3;

FIG. 7 is a cross sectional view schematically illustrating any one stage of unit structures obtained according to A-A line in FIGS. 4 to 6; and

FIG. 8 is a cross sectional view schematically illustrating any one stage of unit structures obtained in a varied example of the structure.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the PC (pre-cast concrete) structure and the method of constructing the same according to preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 3 is a broken view schematically illustrating the PC structure according to a preferred embodiment of the present invention.

As shown in FIG. 3, the PC structure 100 according to this embodiment comprises a plurality of unit structures, wherein 3 unit structures are piled to be one bundle and one bundle of unit structures is piled on another bundle of unit structures.

To help the explanation, the lower piled 3 unit structures is defined as ‘the lower unit structure’, the middle piled 3 unit structures is defined as ‘the middle unit structure’, and the upper piled 3 unit structures is defined as ‘the upper unit structure’. Therefore, the lower unit structure 110, the middle unit structure 130, and the upper unit structure 150 respectively have the lowest stage unit structure, the middle stage unit structure and the highest stage unit structure, which may be understood 1^(st) stage, 2^(nd) stage and 3^(rd) stage from FIG. 3.

FIG. 3 is illustrated to easily explain the representative construction method all together, and the specific construction method will be explained in later after the explanation for each unit structure with reference to FIGS. 4 to 7.

Firstly, the lower unit structure 110 is explained with reference to FIG. 4. FIG. 4 is a cross sectional view schematically illustrating the lower unit structure in FIG. 3.

As shown in FIG. 4, the lower unit structure 110 has the lowest stage unit structure 111, the middle stage unit structure 112, and the highest stage unit structure 113.

The lowest stage unit structure 111 is located undermost, and it is provided with a wedge typed coupler 114 where a cylindrical lower end portion binder 11 to bind a bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof. The wedge typed coupler 114 is cylindrically formed to be corresponded with the cylindrical lower end portion binder 11, and it is slightly longer than the lower end portion binder 11 such that the whole outer surface of the lower end portion binder 11 is wedged.

Further, the lowest stage unit structure 111 is provided with a reinforcing rod guider 115 to guide the insertion of a plurality of heavy reinforcing rods 2 in the upper end portion thereof and in the lower end portion thereof to be very on the wedge typed coupler 114, respectively. The reinforcing rods guiders 115 are vertically installed with the plurality of heavy reinforcing rods 2 thereto. At this time, the upper end portion of the plurality of heavy reinforcing rods 2 is protruded out the upper end of the lowest stage unit structure 111.

This structure will be obtained by desirably placing the wedge typed coupler 114, the plurality of reinforcing rod guiders 115, and the plurality of heavy reinforcing rods 2 in a desired manufacturing frame (not shown) and then by putting concrete in the frame to well harden. Although not shown, a plurality of light reinforcing rods are preferably placed between the plurality of heavy rebar 2. The middle stage unit structure 112 and the highest stage unit structure 113 explained in below are also obtained by the same method described above, and therefore the manufacturing method for the middle and highest stage unit structures 112 and 113 is not further explained.

The middle stage unit structures 112 is provided with a plurality of reinforcing rod couplers 116 which couple the plurality of heavy reinforcing rods 2 in the lower end portion thereof to be located near the through-hole through which the bundle of tension wires 1 are passed. The plurality of reinforcing rod couplers 116 have the upper and lower portions in couple to be one body or to be separated. The upper portion rightly stands up, but the lower portion reversely stands up. One heavy reinforcing rod 2 planted in one corresponding unit structure is wedged in the upper portion, and another heavy reinforcing rod 2 protruded from another unit structure, that is the lowest stage unit structure 111, is wedged in the lower portion.

And, the middle stage unit structure 112 is provided with the reinforcing rod guiders 115 to guide the insertion of the plurality of heavy reinforcing rods 2 in the upper end portion thereof and in the lower end portion thereof to be on the plurality of reinforcing rod couplers 116. These reinforcing rod guiders 115 are vertically installed with the plurality of heavy reinforcing rods 2. At this time, the upper end portion of the plurality of heavy reinforcing rods 2 protrudes out the upper end of the middle unit structure 112.

The highest stage unit structure 113 is not explained because it has the same structure with the middle stage unit structure 112 to avoid the overlapped explanation.

As shown in FIG. 4, the vertically piled the lowest stage unit structure 111, the middle stage unit structure 112 and the highest stage unit structure 113 are firmly combined from each other by the bundle of tension wires 1. The lower end portion binder 11 bound to the lower end portion of the bundle of tension wires 1 is vertically wedged to the wedge typed coupler 114 provided in the lowest stage unit structure 111 by its heavy weight, and the upper end portion binder 12 bounded to the upper end portion of the bundle of tension wires 1 is hung on the upper end of the highest stage unit structure 113.

The upper end portion binder 12 bounded to the upper end portion of the bundle of tension wires 1 is provided with a binding plate 13 having the desired size to be hung on the upper end surface of the highest stage unit structure 113, and therefore the upper end portion binder 12 is located out the highest stage unit structure 113. To firmly combine the lowest, middle and highest stage unit structures 111, 112 and 113 with the bundle of tension wires 1, the length of the tension wires 1 should be slightly shorter than the whole length of the piled lowest, middle and highest stage unit structures 111, 112 and 113 such that the tension force should be vertically given to the piled lowest, middle and highest stage unit structures 111, 112 and 113.

Next, the middle unit structure will be explained with reference to FIG. 5. FIG. 5 is a cross sectional view schematically illustrating the middle unit structure in FIG. 3.

As shown, the middle unit structure 130 has the lowest stage unit structure 131, the middle stage unit structure 132, and the highest stage unit structure 133.

In FIG. 5, the lowest stage unit structure 131 is provided with a wedge typed coupler 134 where a cylindrical lower end portion binder 31 to bind the bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof. At this time, different from the coupler applied to the lowest stage unit structure 111, the wedge typed coupler 134 is composed of the upper portion and the lower portion in couple. The upper portion rightly stands up, but the lower portion reversely stands up. The lower end portion binder 31 to bind the bundle of tension wires 1 inserted in the corresponding unit structure 131 is wedged in the upper portion, and the upper end portion binder 12, which is protruded over uppermost, to bind another bundle of tension wires 1 is wedged in the lower portion.

Herein, the middle stage unit structure 132 and the highest stage unit structure 133 which are piled on the lowest stage unit structure 131 will be not explained because they have the same structure with the middle stage unit structure 112 and the highest stage unit structure 113 which is already explained in FIG. 4, to avoid the overlapped explanation.

These vertically piled lowest, middle and highest stage unit structures 131, 132 and 133 are firmly combined from each other by the bundle of tension wires 1. The lower end portion binder 31 to bind the lower end portion of the bundle of tension wires 1 is vertically wedged in the wedge typed coupler 134 provided in the lowest stage unit structure 131 with its heavy weight, the upper end portion binder 32 to bind the upper end portion of the bundle of tension wires 1 is hung on the upper end of the highest stage unit structure 133.

At this time, the upper end portion binder 32 to bind the upper end portion of the bundle of tension wires 1 is provided with a binding plate 33 having the desired size to be hung on the upper end surface of the highest stage unit structure 133, and therefore the upper end portion binder 32 is located out the highest stage unit structure 133.

To firmly combine the lowest, middle and highest stage unit structures 131, 132 and 133 with the bundle of tension wires 1, the length of the tension wires 1 should be slightly shorter than the whole length of the piled lowest, middle and highest stage unit structures 131, 132 and 133 such that the tension force should be vertically given to the piled lowest, middle and highest stage unit structures 131, 132 and 133.

The middle unit structure 130 obtained like this way will be piled on the lower unit structure 110 shown in FIG. 4 in later. At this time, the empty space in the wedge typed coupler 134 provided in the lowest stage unit structure 131 of the middle unit structure 130 is strongly wedged to the upper end portion binder 12 protruded out the highest stage unit structure 113 of the lower unit structure 110 in FIG. 4 by the heavy weight of the corresponding structure.

Lastly, the upper unit structure will be explained with reference to FIG. 6. FIG. 6 is a cross sectional view schematically illustrating the upper unit structure in FIG. 3.

As shown in FIG. 6, the upper unit structure 150 has the lowest stage unit structure 151, the middle stage unit structure 152 and the highest stage unit structure 153.

Herein, the lowest stage unit structure 151, the middle stage unit structure 152 are not explained because they have the same structure with the lowest stage unit structure 131 and the middle stage unit structure 132 which are already explained in FIG. 5, to avoid the overlapped explanation.

The highest stage unit structure 153 is provided with a wedge typed coupler 154 where a upper end portion binder 52 to bind to bind the bundle of tension wires 1 is wedged to be intermediately located in the upper end portion thereof. At this time, the wedge typed coupler 154 has the same structure with the coupler applied to the lowest stage unit structure in FIG. 4, but it reversely stands up.

These vertically piled lowest, middle and highest stage unit structures 151, 152 and 153 are firmly combined from each other by the bundle of tension wires 1. The lower end portion binder 51 to bind the lower end portion of the bundle of tension wires 1 is vertically wedged in the wedge typed coupler 154 provided in the lowest stage unit structure 151 with its heavy weight, and the upper end portion binder 52 to bind the upper end portion of the bundle of tension wires 1 is hung on the upper end of the highest stage unit structure 153.

At this time, the upper end portion binder 52 to bind the upper end portion of the bundle of tension wires 1 is provided with a binding plate 53 having the desired size to be hung on the upper end surface of the highest stage unit structure 153, and the lower end portion binder 51 is located in the highest stage unit structure 153. To firmly combine the lowest, middle and highest stage unit structures 151, 152 and 153 with the bundle of tension wires 1, the length of the tension wires 1 should be slightly shorter than the whole length of the piled lowest, middle and highest stage unit structures 151, 152 and 153 such that the tension force should be vertically given to the piled lowest, middle and highest stage unit structures 151, 152 and 153.

FIG. 7 is a cross sectional view schematically illustrating any one stage of unit structures obtained according to A-A line in FIGS. 4 to 6.

As shown in FIG. 7, the reinforcing rod guider 115 is installed such that four heavy reinforcing rods 2 are located near four corners of the rectangular unit structure. The reinforcing rod guider 115 is composed of a plurality of circular inserting portions 116 to be inserted with the plurality of heavy reinforcing rods 2 and a plurality of connecting portions 117 to connect the inserting portions 116. As shown, the light reinforcing rods are planted around the heavy reinforcing rods 2.

FIG. 7 illustrates the unit structure having the rectangular section surface, but alternatively, the unit structure may have the circular section surface like FIG. 8.

As shown in FIG. 8, the reinforcing rod guider 115 is installed such that four heavy reinforcing rods 2 are located near four corners of the circular unit structure. The reinforcing rod guider 115 is composed of the plurality of circular inserting portions 116 to be inserted with the heavy reinforcing rods 2 and the plurality of connecting portion 117 to connect the inserting portions 116. As shown, the light reinforcing rods are planted around the heavy reinforcing rods 2.

The construction method of the PC structure of the present invention will be briefly explained with reference to FIG. 1.

Firstly, as shown in FIG. 4, on site, the lowest stage unit structure 111, the middle stage unit structure 112 and the highest stage unit structure 113 are vertically orderly piled so as to make the lower unit structure 110.

Next, as shown in FIG. 5, the lowest stage unit structure 131, the middle stage unit structure 132 and the highest stage unit structure 133 are vertically orderly piled so as to make the middle unit structure 130.

Next, as shown in FIG. 6, the lowest stage unit structure 151, the middle stage unit structure 152 and the highest stage unit structure 153 are vertically orderly piled so as to make the upper unit structure 150.

Lastly, the middle unit structure 130 is vertically piled on the lower unit structure 110, and the upper unit structure 150 is vertically piled on the middle unit structure 130.

Herein, the middle unit structure 130 is applied just one time, but its number may be changed according to the height of the desired structure to be constructed.

Although the preferred embodiment of the present invention have been described, it is understood that the present invention should not be limited to this preferred embodiment but various changes and modifications can be made by one skilled in the art within the sprit and scope of the present invention aimed. 

1. A pre-cast concrete structure, the structure comprising: a lower unit structure 110 having the lowest stage unit structure 111, the middle stage unit structure 112, and the highest stage unit structure 113 which are vertically orderly piled on another and wedged from each other; a middle unit structure 130 having the lowest stage unit structure 131, the middle stage unit structure 132, and the highest stage unit structure 133 which are vertically orderly piled on another and wedged from each other; and a upper unit structure 150 having the lowest stage unit structure 151, the middle stage unit structure 152, and the highest stage unit structure 153 which are vertically orderly piled on another and wedged from each other.
 2. The pre-cast concrete structure according to claim 1, wherein all stage unit structures composed of the lower unit structure 110, the middle unit structure 130 and the upper unit structure 150 are provided with a reinforcing rod guider 115 to guide a plurality of heavy reinforcing rods 2, respectively.
 3. The pre-cast concrete structure according to claim 2, wherein the reinforcing rod guider 115 is composed of a plurality of inserting portions 116 to be inserted with the plurality of heavy reinforcing rods 2 and a plurality of connecting portions 117 to connect the plurality of inserting portions
 116. 4. The pre-cast concrete structure according to claim 1, wherein the lower unit structure 110, the middle unit structure 130 and the upper unit structure 150 are further firmly combined by a bundle of tension wires 1 which pass through them.
 5. The pre-cast concrete structure according to claim 4, wherein the lowest stage unit structure 111 is provided with a wedge typed coupler 114 where a lower end portion binder 11 to bind the bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof.
 6. The pre-cast concrete structure according to claim 4, wherein the middle stage unit structures 112 is provided with a plurality of reinforcing rod couplers 116 which couple the plurality of heavy reinforcing rods 2 in the lower end portion thereof to be located near the through-hole through which the bundle of tension wires 1 are passed.
 7. The pre-cast concrete structure according to claim 6, wherein the plurality of reinforcing rod couplers 116 have a upper portion and a lower portion in couple, the upper portion rightly standing up and the lower portion reversely standing up.
 8. The pre-cast concrete structure according to claim 4, wherein the highest stage unit structure 113 has the same structure with the middle stage unit structure
 112. 9. The pre-cast concrete structure according to claim 1, wherein the lowest stage unit structure 131 is provided with a wedge typed coupler 134 where a lower end portion binder 31 to bind the bundle of tension wires 1 is wedged to be intermediately located in the lower end portion thereof, and the wedge typed coupler 134 is composed of the upper portion and the lower portion in couple, the upper portion rightly standing up and the lower portion reversely standing up.
 10. The pre-cast concrete structure according to claim 9, wherein the lower end portion binder 31 inserted in the lowest stage unit structure 131 is wedged in the upper portion, and the upper end portion binder 12 to bind another bundle of tension wires 1 protruded out the highest stage unit structure 113 is wedged in the lower portion.
 11. The pre-cast concrete structure according to claim 1, wherein the highest stage unit structure 153 is provided with a wedge typed coupler 154 where a upper end portion binder 52 to bind the bundle of tension wires 1 is wedged to be intermediately located in the upper end portion thereof, the wedge typed coupler 154 reversely standing up.
 12. A method of constructing the pre-cast concrete structure as claimed in claim 1, the method comprising: (A) step for vertically orderly piling the lowest stage unit structure 111, the middle stage unit structure 112 and the highest stage unit structure 113 so as to make a lower unit structure 110; (B) step for vertically orderly piling the lowest stage unit structure 131, the middle stage unit structure 132 and the highest stage unit structure 133 so as to the middle unit structure 130; (C) step for vertically orderly piling the lowest stage unit structure 151, the middle stage unit structure 152 and the highest stage unit structure 153 so as to make the upper unit structure 150; and (D) step for vertically piling the middle unit structure 130 on the lower unit structure 110, and then vertically piling the upper unit structure 150 on the middle unit structure
 130. 13. The method of constructing the pre-cast concrete structure according to claim 12, wherein the number of the middle unit structure 130 is changed according to the height of the desired structure to be constructed. 